US7025923B2 - Methods for forming complex-shaped components in a heated polymeric film - Google Patents
Methods for forming complex-shaped components in a heated polymeric film Download PDFInfo
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- US7025923B2 US7025923B2 US10/226,433 US22643302A US7025923B2 US 7025923 B2 US7025923 B2 US 7025923B2 US 22643302 A US22643302 A US 22643302A US 7025923 B2 US7025923 B2 US 7025923B2
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- protrusion
- forming tool
- shape
- sidewalls
- distal end
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/08—Deep drawing or matched-mould forming, i.e. using mechanical means only
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
- A61B1/00—Instruments for performing medical examinations of the interior of cavities or tubes of the body by visual or photographical inspection, e.g. endoscopes; Illuminating arrangements therefor
- A61B1/00064—Constructional details of the endoscope body
- A61B1/0011—Manufacturing of endoscope parts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/10—Forming by pressure difference, e.g. vacuum
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
- A61B1/00—Instruments for performing medical examinations of the interior of cavities or tubes of the body by visual or photographical inspection, e.g. endoscopes; Illuminating arrangements therefor
- A61B1/00163—Optical arrangements
- A61B1/00165—Optical arrangements with light-conductive means, e.g. fibre optics
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2791/00—Shaping characteristics in general
- B29C2791/004—Shaping under special conditions
- B29C2791/006—Using vacuum
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
- B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
- B29K2995/0026—Transparent
- B29K2995/0027—Transparent for light outside the visible spectrum
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/753—Medical equipment; Accessories therefor
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S264/00—Plastic and nonmetallic article shaping or treating: processes
- Y10S264/78—Processes of molding using vacuum
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S600/00—Surgery
- Y10S600/92—Method of making endoscopes
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
- Y10T428/1334—Nonself-supporting tubular film or bag [e.g., pouch, envelope, packet, etc.]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
- Y10T428/1352—Polymer or resin containing [i.e., natural or synthetic]
Definitions
- the present invention is directed toward a method of making medical components, and more particularly toward a method of making contoured, thin-walled, complex-shaped medical components usable with intrabody medical devices.
- intrabody medical equipment such as endoscopes, catheters, and the like
- endoscopes have been optimized and refined so as to provide upper endoscopes for the examination of the esophagus, stomach, and duodenum, colonoscopes for examining the colon, angioscopes for examining blood vessels, bronchoscopes for examining the bronchii, laparoscopes for examining the peritoneal cavity, arthroscopes for examining joint spaces, nasopharygoscopes for examining nasal passages and pharynx, and intubation scopes for examination of a person's airway.
- a conventional endoscope 10 shown in FIG. 1 , has an insertion tube 12 that is connected at its proximal end 14 to a handle or control body 16 .
- the insertion tube 12 is adapted to be inserted into a patient's body cavity to perform a selected therapeutic or diagnostic procedure.
- the insertion tube 12 contains an imaging system 18 having optical fibers or the like extending along the length of the insertion tube and terminating at a viewing window 19 in the insertion tube's distal end 20 .
- the imaging system 18 conveys an image from the viewing window 19 to an eyepiece 22 on the control body 16 or to a monitor (not shown), so the user can see into a selected body cavity during an endoscopic procedure.
- the endoscope 10 is described in greater detail in U.S. Pat. No. Re 34,110 and U.S. Pat. No. 4,646,722, which are incorporated by reference herein.
- a conventional sheath assembly 24 shown partially cut away for illustrative purposes, includes a flexible, elastic sheath 26 that tightly surrounds the endoscope's insertion tube 12 .
- the sheath 26 may also contain one or more working channels 32 that extend along the insertion tube 12 and that are adapted to receive conventional endoscopic accessories therethrough without contaminating the endoscope itself during the endoscopic procedure.
- the sheath 26 has a distal end portion 21 that includes an endcap 34 having a transparent window 28 positioned to cover the viewing window 19 at the insertion tube's distal end 20 when the sheath assembly is installed.
- the endcap 34 is formed of a relatively rigid material and is sealably secured to the sheath's distal end portion 21 .
- the complex-shaped endcap can be a costly and laborious component to manufacture for the sheath assembly.
- Other thin-walled components that would be required to have a complex shape if used with endoscopic sheaths or other medical devices having complex shapes may include precision detent mechanisms and short-pitched threads that are manufactured with the necessary accuracy and tolerances required for intricate-medical devices.
- U.S. Pat. No. 5,443,781 to Saab teaches a method of forming a disposable sheath with an optically transparent window that is integral with the sheath.
- the transparent window is formed so as to maintain a thin-walled, relatively inelastic, yet flexible sheath for an optical medical instrument.
- Saab teaches forming the sheath by heating a sheet or film of optically transparent polymeric material until the material's viscosity is substantially reduced and the film is malleable. As shown in FIG. 2 , a mandrel 35 having a relatively simply cylindrical shape is thrust into the heated film 37 causing the film to stretch and to generally conform to the mandrel's shape.
- the heated film 37 is formed into a closed-end sheath 39 having sidewalls 36 , a flange or collar 38 at its open proximal end 40 , and a closed distal end 42 .
- the mandrel 35 is selected based upon its simple geometrical shape to define the shape of the sheath 39 . Accordingly, sheaths having different shapes and sizes are formed using different mandrels with the corresponding shapes and sizes.
- the sheath and technique of making the sheath as discussed in Saab results in the film being heated, stretched, and then cooled to remain the shape that generally corresponds to the mandrel's simple shape.
- the resulting sheath is limited to having a relatively simple geometrical shape.
- the method of Saab does not sufficiently allow for making complex-shaped components having close tolerances.
- the present invention provides a method capable of forming complex-shaped medical components in a heated polymeric film to provide thin-walled, durable, low-cost components that may be manufactured to close tolerances, which has been problematic in the prior art.
- the method of forming a thin-walled polymeric component includes the steps of heating a portion of the polymeric film to a malleable temperature, and using a forming tool to form a protrusion in the film's heated portion while the polymeric film is malleable.
- the formed protrusion has an open proximal end, a distal end spaced apart from the proximal end, and sidewalls extending between the proximal and distal ends.
- the sidewalls and distal end define a first shape of the protrusion and also define an interior of the protrusion.
- the forming tool has a shaping portion that may have a selected complex shape that is different than the protrusion's first shape.
- the method further includes the step of exerting a force radially inwardly on the protrusion and moving the protrusion into firm engagement with the forming tool's shaping portion so the protrusion moves from the first shape to a second shape that closely conforms to the selected shape of the forming tool's shaping portion.
- the radially inward force exerted on the protrusion is achieved by creating a differential pressure so the pressure within the interior of the protrusion is less than the pressure outside the protrusion, thereby causing the protrusion's sidewalls to move inwardly to the second shape.
- the step of exerting a differential pressure on the protrusion is achieved by drawing a partial vacuum inside the protrusion. The partial vacuum may be drawn through the forming tool and through at least one vacuum port in the forming tool.
- the present invention is also directed toward a polymeric medical component that may have a selected complex shape that is made by the above-described process.
- the present invention is also directed toward a vacuum-forming tool capable of forming the medical component from a malleable polymeric protrusion.
- the vacuum-forming tool includes a shaft having an air passageway and a forming portion, and the forming portion has a shape corresponding to the selected shape of the medical component.
- the forming portion has an outer surface and a plurality of apertures extending from the outer surface to the air passageway.
- the shaft is connectable to a vacuum source so the air passageway communicates with the vacuum source to allow the vacuum source to draw air through the apertures into the air passageway, thereby forming a partial vacuum within the malleable polymeric protrusion during the formation of the medical component.
- FIG. 1 is an isometric view of a prior art endoscope and endoscopic sheath assembly.
- FIG. 2 is an isometric view of a thermal plastic film of the prior art stretched by a mandrel.
- FIG. 3 is an isometric view of a distal portion of an endoscopic sheath having a thin-walled, polymeric endcap formed in accordance with one embodiment of the present invention.
- FIG. 4 is an isometric view of a heated thin-walled polymeric film with a funnel-shaped projection formed therein in accordance with one embodiment of the present invention and shown in an extended position, and a complex-shaped forming tool is shown positioned in the protrusion and connected to a vacuum source.
- FIG. 5 is an isometric view of the heated polymeric film of FIG. 4 with the projection shown in a contracted position in solid lines on the forming tool, and the projection is shown in the extended position in phantom lines.
- FIG. 6 is an isometric view of the protrusion of FIG. 5 shown with a distal portion of the protrusion being separated from a proximal portion to provide the selected thin-walled polymeric endcap with complex shape.
- FIG. 7 is an isometric view of an alternate embodiment of the present invention with the thin-walled component having close-pitched threads formed therein by a complex-shaped threaded forming tool shown in phantom lines.
- FIG. 8 is an isometric view of an alternate embodiment of the present invention with the thin-walled component having detents formed therein by a forming tool shown in phantom lines.
- a thin-walled polymeric medical component 50 having a complex shape made in accordance with one embodiment of the present invention is described herein with reference to the attached drawings.
- An exemplary embodiment of a thin-walled medical component 50 shown in FIG. 3 , is attached to a distal end 52 of a sheath 54 .
- the sheath 54 is shaped and sized to receive and isolate, as an example, an endoscope insertion tube 56 shown in phantom lines.
- the illustrated medical component 50 is a sheath endcap 51 that is sealably attached to the sheath's distal end 52 so as to provide a viewing window therein that allows clear imaging through the endoscope's imaging system 58 , also shown in phantom lines.
- the distal end portion 55 of the illustrated insertion tube 56 has a generally C-shaped cross-section and the endcap 51 is formed with a corresponding complex geometrical shape that closely conforms to the insertion tube's distal end portion. More specifically, the C-shaped cross-section of the illustrated endcap 51 is defined by a curved outer axial wall 60 that has a selected radius and a curved inner axial wall 62 that is integrally connected to the outer axial wall 60 .
- the inner axial wall 62 has a radius which is smaller than the radius of the outer axial wall 60 .
- the inner axial wall 62 defines a receiving area 64 that is shaped and sized to receive one or more selected working channels 66 , shown in phantom lines, extending through the sheath 54 .
- the illustrated endoscopic sheath 54 includes a tubular working channel 66 that extends through the sheath and that is sealably connected to the sheath's distal end 52 .
- the tubular working channel 56 snugly fits in the endcap's receiving area 64 , while the distal end of the endoscope's insertion tube 56 is snugly received in the endcap 51 between the inner and outer walls.
- the thin-walled endcap 51 is provided with a complex geometrical shape that receives and retains the insertion tube's distal end therein and retains the working channel 66 adjacent to the distal end while minimizing the cross-sectional area of the sheath and insertion tube combination which is to be inserted into a patient.
- the medical component 50 such as the end cap 51
- the method of making the component is discussed herein with reference to an endoscopic sheath
- the method of the present invention is equally applicable to medical components used in procedures for medical devices other than endoscopic procedures.
- the medical component 50 in alternate embodiments are complex-shaped components used with catheters, optical medical equipment, and non-optical imaging medical equipment.
- the thin-walled polymeric medical component 50 is made by forming a thin polymeric film into the desired shape.
- the preferred polymeric film used with the present invention is a thermoplastic material including PVC, acrylic, polycarbonate, polyethylene terephthalate, or other thermoplastic polyester material.
- the polymeric material used by the present invention allows for thin-walled medical components that are substantially inelastic, flexible, and have high strength, and that can be easily, inexpensively, and quickly manufactured.
- the polymeric film is selected so the medical component 50 has a wall thickness in the range of approximately 0.0005 to 0.015 inches, inclusive, and preferably in the range of approximately 0.0008 to 0.005 inches, inclusive.
- the medical component 50 is formed from a material that is optically transparent to visible light.
- the polymeric film may be selected to provide a desired degree of transparency to electromagnetic radiation in the visible spectrum, or in the non-visible spectrum, e.g., radar, laser, or microwave.
- the polymeric film may also be selected, when needed, to provide a desired degree of transparency to sound waves, such as for use with ultrasound devices.
- the polymeric film 68 is retained in a selected position so as to substantially define a plane.
- An interior portion of the film 68 is heated by a conventional heating device 72 to a selected malleable temperature to form a malleable, heated portion 70 of the film.
- the heated portion 70 is then stretched and formed into a protrusion 80 , as discussed in greater detail below, by a forming tool 74 .
- the forming tool 74 has a contoured shaping portion 78 with a complex geometrical shape that corresponds to the shape of the endcap or other medical component to be formed.
- the forming tool's shaping portion 78 has a C-shaped cross-section with curved inner and outer surfaces that correspond to the endcap's C-shaped cross-section discussed above.
- the forming tool's shaping portion 78 is pressed into the heated portion generally perpendicular to the plane defined by the film 68 , and the forming tool stretches the heated portion away from the plane to form a thin-walled, generally funnel-shaped protrusion 80 .
- the protrusion 80 has an open proximal end 82 , a closed distal end 84 spaced away from the open proximal end and sidewalls 86 extending between the proximal and distal ends.
- the closed distal end 84 and the sidewalls 86 define an interior 88 of the protrusion 80 that contains the forming tool's shaping portion 78 as the protrusion is formed.
- the protrusion 80 As the protrusion 80 is formed, the protrusion has a generally tubular shape that only roughly conforms to the outer shape of the forming tool's shaping portion 78 , but the protrusion's sidewalls 86 do not yet closely conform to the complex shape of the forming tool's shaping portion.
- the protrusion's sidewalls 86 conform to the shaping portion's outer curved surface but do not conform to the shaping portion's inner curved surface, such that the protrusion has a generally D-shaped cross-section, rather than the C-shaped cross-section of the shaping portion.
- the protrusion's sidewalls 86 and the closed distal end 84 are then brought into firm and close engagement with the forming tool's shaping portion 78 , as shown in FIG. 5 , thereby closely conforming to the shaping portion's complex geometrical shape.
- the protrusion 80 is brought into firm engagement with the shaping portion 78 by drawing a partial vacuum within the projection's interior 88 .
- the partial vacuum causes a differential pressure in the protrusion that is exerted on the sidewalls 86 , so the pressure within the protrusion is less than the pressure outside of the protrusion.
- the partial vacuum moves the protrusion's sidewalls 86 against the forming tool's shaping portion 78 to achieve the selected complex geometrical shape for the medical component 50 .
- the forming tool 74 is removed from the protrusion's interior 88 and the protrusion remains in the contracted position.
- the forming tool 74 is a partially hollow member with at least one and preferably a plurality of vacuum ports 89 formed in the shaping portion 78 .
- the forming tool 74 is connected to a conventional vacuum source 90 by a vacuum line 92 .
- the vacuum source is adapted to draw air into the forming tool's shaping portion 78 through the vacuum ports 89 , thereby creating the partial vacuum within the interior.
- a distal portion of the protrusion 80 which has the complex-shape formed therein, is cut or otherwise separated from the remaining portion of the protrusion, and that distal portion is the thin-walled polymeric medical component 50 .
- the component 50 such as the illustrated C-shaped endcap 51 , is then connected to the selected medical device, such as the distal end 52 of the endoscopic sheath 54 , as illustrated in FIG. 3 .
- the protrusion 80 is moved to the contracted position by exerting substantially uniform, exterior pressure on the protrusion in a radially inward direction.
- the distal portion of the protrusion 80 and the forming tool's shaping portion 78 are positioned, as a unit, within a pneumatic pressure-generating device or other suitable device that exerts the exterior pressure, and the pressure generating device moves the protrusion's sidewalls 86 from the expanded position to the contracted position and into close engagement with the forming tool's shaping portion 78 .
- the radially inward directed forces on the protrusion 80 may be achieved by generating a vacuum in the protrusion's interior or by creating a pressure external to the protrusion.
- the preferred method is to use the partial vacuum within the protrusion's interior 88 because the partial vacuum does not disturb the temperature profile of the heated polymeric film.
- the disclosed embodiment of the present invention also allows easy and inexpensive formation of a thin-walled, polymeric medical component 50 having close-pitched, accurately-located threads formed therein.
- the forming tool 74 has a plurality of close-pitched threads 100 formed in the shaping portion 78 .
- the forming tool 74 is pressed into the heated portion 70 of the polymeric film 68 when at malleable temperature, thereby forming the protrusion 80 .
- the protrusion's sidewalls 86 are generally adjacent to the threads 100 on the forming tool 74 , but do not yet closely conform to the threads.
- the differential pressure is then generated in the protrusion's interior 88 , moving the sidewalls 86 to the contracted position and into close engagement with the threads 100 , thereby forming the close-pitched, accurately positioned threads 102 in the protrusion.
- the forming tool 74 is then removed preferably by rotating it so the shaping portion 78 unscrews from the threads 102 formed in the protrusion 80 .
- the present invention also allows for easy and inexpensive formation of a thin-walled polymeric medical component 50 , as shown in FIG. 8 , having precisely located detents 120 formed in selected positions that correspond to detent receiving portions on a selected medical device, not shown.
- the medical component 50 may also have a concave-shaped distal end 122 that follows the contour of the selected medical device.
- the medical component 50 illustrated in FIG. 8 is formed using a forming tool 74 with a shaping portion 78 having one or more detent molds 124 in a selected position and having a concave distal end surface 125 .
- the shaping portion 78 also has the vacuum ports 89 formed therein for creating the partial vacuum in the protrusion's interior portion 88 .
- the protrusion's sidewalls 86 are drawn into firm engagement with the forming tool's detent molds 124 so as to form the detents 120 in the protrusion.
- the protrusion's closed distal end 84 is drawn into firm engagement with the forming tool's concave distal end 125 , thereby forming a medical component 50 with a concave closed distal end.
- the forming tool 74 is removed from the protrusion's interior 88 and the selected shaping portion of the protrusion 80 is cut in order to remove the complex-shaped medical component 50 from the rest of the protrusion.
- the forming tool 74 may be removed from the protrusion's interior 88 by slightly deflecting the sidewalls 86 of the protrusion 80 until sufficient clearance is provided between the sidewalls and the forming tool's shaping portion 78 . Such deflection is possible because the thin-walled polymeric material is sufficiently flexible to move so as to allow removal of the forming tool without permanent deformation of the medical component 50 .
- the thin-walled polymeric medical component 50 is formed by stretching or drawing the protrusion 80 in two or more steps, so selected portions of the component have a different thickness than the thickness of other portions of the component.
- an endcap with an integral optical lens is formed by pressing a first forming tool 74 into the heated portion 70 to form the protrusion 80 , and the differential pressure is applied to the protrusion, as discussed above.
- the first forming tool 74 is specifically designed to form the lens of the endcap to provide the selected thickness and optical characteristics of the lens.
- the first forming tool is removed from the protrusion 80 . While the protrusion 80 is still malleable, a second forming tool is pressed into the protrusion to further draw or stretch the protrusion's sidewalls 86 to form thinner sidewalls.
- the second forming tool is designed to support the lens portions so there is substantially no further drawing of the lens while the sidewalls 86 are being drawn.
- the differential pressure is exerted on the protrusion so the protrusion conforms to the second forming tool, and the second forming tool is then removed. Accordingly the lens maintains its selected thickness, and the sidewalls are thinner than when formed by the first forming tool.
- the protrusion 80 is formed with portions having different thicknesses by heating the film 68 a first time and forming the protrusion with a forming tool as discussed above. The protrusion 80 is then allowed to cool to below the malleable temperature. A selected portion of the protrusion 80 , such as the sidewalls 86 , is heated a second time to the malleable temperature, and the sidewalls or other selected portion is further stretched or drawn with the same or a different forming tool. Accordingly, the protrusion's selected portion that is reheated and further drawn is thinner while the protrusion's other portions that were not heated a second time are not further thinned by the second drawing process.
- the thin-walled polymeric medical component 50 is formed by pressing the forming tool 74 into the polymeric film's heated portion 70 , such that the distal end of the forming tool pierces the distal end of the protrusion.
- the protrusion's sidewalls are substantially sealably connected to the forming tool's shaping portion 78 , so a partial vacuum can still be generated to draw the sidewalls into firm engagement with the shaping portion.
- the complex-shaped medical component 50 is further modified or machined after formation of the component so as to remove or modify a selected portion of the medical component.
- polymeric material is removed from a distal end portion of a selected medical component to allow a selected medical device to be positioned partially within the component, while a selected portion of the device extends through the thin-walled polymeric medical component.
- the thin-walled, polymeric medical component can be formed with a selected complex shape for use with a wide range of medical devices.
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Abstract
Description
EXHIBIT A |
Appl. No. | Atty Dkt # | Applicants | Filed | Title |
08/948,615 | 500598.01 | J. M. | Oct. 10, | Apparatus and |
(930058.419) | Goodard, | 1997 | Method for Form- | |
E. P. | ing Complex- | |||
Harhen | Shaped Compon- | |||
ents in a Heated | ||||
Polymeric Film | ||||
09/366,950 | 500598.02 | J. M. | Aug. 4, | Apparatus and |
(930058.419D1) | Goodard, | 1999 | Method for Form- | |
E. P. | ing Complex- | |||
Harhen | Shaped Compon- | |||
ents in a Heated | ||||
Polymeric Film | ||||
Claims (37)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US10/226,433 US7025923B2 (en) | 1997-10-10 | 2002-08-22 | Methods for forming complex-shaped components in a heated polymeric film |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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US94861597A | 1997-10-10 | 1997-10-10 | |
US09/366,950 US6579582B1 (en) | 1997-10-10 | 1999-08-04 | Apparatus and method for forming complex-shaped components in a heated polymeric film |
US10/226,433 US7025923B2 (en) | 1997-10-10 | 2002-08-22 | Methods for forming complex-shaped components in a heated polymeric film |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US09/366,950 Division US6579582B1 (en) | 1997-10-10 | 1999-08-04 | Apparatus and method for forming complex-shaped components in a heated polymeric film |
Publications (2)
Publication Number | Publication Date |
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US20030008083A1 US20030008083A1 (en) | 2003-01-09 |
US7025923B2 true US7025923B2 (en) | 2006-04-11 |
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US09/366,950 Expired - Lifetime US6579582B1 (en) | 1997-10-10 | 1999-08-04 | Apparatus and method for forming complex-shaped components in a heated polymeric film |
US10/226,433 Expired - Lifetime US7025923B2 (en) | 1997-10-10 | 2002-08-22 | Methods for forming complex-shaped components in a heated polymeric film |
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US09/366,950 Expired - Lifetime US6579582B1 (en) | 1997-10-10 | 1999-08-04 | Apparatus and method for forming complex-shaped components in a heated polymeric film |
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US9433468B2 (en) | 2013-10-04 | 2016-09-06 | Tidi Products, Llc | Sheath for a medical or dental instrument |
US9510743B2 (en) | 2013-12-17 | 2016-12-06 | Biovision Technologies, Llc | Stabilized surgical device for performing a sphenopalatine ganglion block procedure |
US9694163B2 (en) | 2013-12-17 | 2017-07-04 | Biovision Technologies, Llc | Surgical device for performing a sphenopalatine ganglion block procedure |
US9839347B2 (en) | 2013-12-17 | 2017-12-12 | Biovision Technologies Llc | Method of performing a sphenopalatine ganglion block procedure |
US10016580B2 (en) | 2013-12-17 | 2018-07-10 | Biovision Technologies, Llc | Methods for treating sinus diseases |
US10046143B2 (en) | 2013-12-17 | 2018-08-14 | Biovision Technologies Llc | Surgical device for performing a sphenopalatine ganglion block procedure |
US10420459B2 (en) | 2013-12-17 | 2019-09-24 | Biovision Technologies, Llc | Method of performing a sphenopalatine ganglion block procedure |
US9516995B2 (en) | 2013-12-17 | 2016-12-13 | Biovision Technologies, Llc | Surgical device for performing a sphenopalatine ganglion block procedure |
US10589072B2 (en) | 2013-12-17 | 2020-03-17 | Biovision Technologies, Llc | Methods for treating sinus diseases |
US11058855B2 (en) | 2013-12-17 | 2021-07-13 | Biovision Technologies, Llc | Surgical device for performing a sphenopalatine ganglion block procedure |
US9248266B2 (en) | 2013-12-17 | 2016-02-02 | Biovision Technologies, Llc | Method of performing a sphenopalatine ganglion block procedure |
USD731652S1 (en) | 2014-02-19 | 2015-06-09 | Tidi Products, Llc | Dental curing light sleeve |
CN105962917A (en) * | 2016-06-08 | 2016-09-28 | 深圳北芯生命科技有限公司 | Measuring conduit and manufacturing method thereof |
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